A red square-body K5 Blazer with a white removable top on wet mud flats below rocky hills in the San Gabriel Canyon off-road area, California, with a Jeep and a pickup nearby
CHEVROLET K5 BLAZER · GMC JIMMY · SQUARE BODY · 1973–1991

Chevrolet K5 Blazer (1973–1991)

350 SMALL-BLOCK V86.2 DIESEL V8 (1982+)NP205 · NP203 · NP208 · NP241DANA 44 / 10-BOLT FRONTREMOVABLE REAR TOPM1009 CUCV

“It's a half-ton pickup with the back seat where the bed should be and a roof you can unbolt. It has a small-block V8 you can fix with a wrench, axles that half the junkyard will fit, and a frame that cracks at the steering box. Owners love it anyway, and it's one of the easiest classic 4x4s to keep on the trail.”

PART 01

Overview

Where it came from, why it matters, and how it changed year to year.

The story

For 1973 General Motors redesigned its whole light-truck line. GM called it the 'Rounded Line', but everyone else calls it the square body, and the K5 Blazer came along with it. The formula stayed the same: take a four-wheel-drive half-ton pickup, shorten it, and make the roof removable. The new Blazer was 7 inches longer than the first generation on a wheelbase 2.5 inches longer. It stayed in production for 19 model years, through two facelifts, a diesel and an Army contract. GMC sold the same truck as the Jimmy, and the long-wheelbase Suburban as the GMC Suburban.

A PICKUP WITH THE ROOF OPTIONAL

The K5 was built as an answer to the International Scout and the Ford Bronco. Because it shared its platform with the C/K pickups, it was bigger, roomier and more stable on the road than either. It also cost less to build, and buyers could add pickup options such as automatic transmissions, air conditioning and radios. By 1970 it was outselling its rivals. Rivals soon copied the idea. Jeep shortened its Gladiator into the Cherokee for 1974, and Ford moved the Bronco onto the F-100 platform for 1978.

From 1973 to 1975 the Blazer was a fully open truck behind the windshield, with a choice of a removable hardtop or a convertible top. In 1976 GM made it a half-cab: a fixed steel roof over the front seats, which improved rollover protection and shared more parts with the pickups, and a removable fiberglass top over the back. That rear top still came off in 1991. The tailgate had a glass window that wound down inside it, either by hand crank or by an electric motor. The motor is a known weak point, so many of these windows no longer work.

SMALL BLOCKS, ONE DIESEL AND FOUR TRANSFER CASES

The 250 straight-six was the base engine until 1982. Most buyers chose a small-block V8: a 307, 305 or 350, or from 1975 a 400. In 1973 Popular Science tested a 175 hp 350 automatic with full-time 4WD. It took 22.5 seconds to reach 60 mph, and the testers recorded 9.6 mpg at a steady 45 mph. For 1982 GM added a 6.2-liter diesel V8 developed with Detroit Diesel. It made 130 hp and 240 lb-ft at launch and fit the same mounts as the gas V8. In 1987 throttle-body injection arrived, and after that the TBI 350 was the standard engine.

Transfer cases tell you the truck's age. From 1973 to 1980 you got either the gear-driven, part-time NP205 or the chain-driven, full-time NP203 with a lockable center differential. GM dropped full-time 4WD after 1979. For 1981 the aluminum NP208 arrived, a part-time case you could shift into 4WD at up to 25 mph, along with automatic locking hubs. From 1989 the NP241 replaced it. Up front, early trucks had a Dana 44, and GM switched to its own corporate 10-bolt from 1977. The rear axle was a 12-bolt, then a 10-bolt. A full-floating 14-bolt from a three-quarter-ton truck is the swap owners usually make.

SILVERADO, CHEYENNE AND THE ARMY

Trim levels followed the pickups. Custom Deluxe was the base model. Cheyenne added carpet, a headliner and extra insulation, and from 1975 Silverado was the top trim. Cheyenne trucks are usually 1970s models, because the name was dropped after 1981 and came back as a lower trim on the 1989–91 R/V trucks. Silverado ran to the end. GMC's Jimmy used Sierra names. In 1976 and 1977 a camper conversion was also offered: about 1,800 Blazer Chalet and Jimmy Casa Grande trucks with a pop-up camper body built by Chinook.

Then the Army bought some. Between 1983 and 1987 GM built the M1009, a K5 rated at three-quarter-ton capacity, as part of its Commercial Utility Cargo Vehicle program. It used the 6.2 diesel, a TH400 automatic and an NP208 transfer case. GM built about 70,000 CUCVs of all types, and many have since gone through government surplus sales. Some were replaced by the Humvees they had been bought to supplement. Ex-military M1009s now come up for sale regularly, and one sold on Bring a Trailer for $20,500 in 2026.

HOW IT ENDED

When the smaller S-10 Blazer appeared in 1983, GM officially renamed the big one the 'Full-Size Blazer' and the GMC version the 'K-Jimmy'. For 1987 the old trucks were renamed the R/V series, because the new GMT400 pickups took over the C/K name, and the Jimmy became the V-Jimmy. The Blazer, Suburban and crew cabs stayed on the old chassis. In 1988 the K5 badges disappeared. The 1989 trucks got a flatter grille in the style of the GMT400, plus the NP241 and 30-spline 10-bolt axle shafts. Rear anti-lock brakes and double-sided galvanized panels arrived for 1990.

1991 was the last year. The 1992 replacement moved to the GMT400 platform with a fixed roof, the Jimmy became the GMC Yukon, and in 1995 the full-size Blazer was renamed Tahoe. The square-body K5 is now an affordable classic that's very easy to modify. On Bring a Trailer, stock trucks often sell for less than $30,000, while LS-swapped restomods have reached six figures.

SIDEBAR · THE ARMY BLAZER

M1009 CUCV: a K5 with a 24-volt system

Around 1976 Vic Hickey, known as the father of the Humvee, used a K5 as a test vehicle for what became the CUCV program. The production M1009 had no air conditioning, an extra leaf in the springs, blackout lights, a brush guard, a rifle rack and paint in olive drab, woodland camouflage or desert tan. It ran on 10.00-15 tires and 3.08 gears, with open 10-bolt axles front and rear except for an Eaton automatic locker in the rear. It was rated for 1,200 lb of payload and a 3,000 lb towed load.

The odd part is the electrics. Two 12-volt alternators and two batteries are wired in series. The starter, the injection pump, the glow-plug circuit and the NATO slave receptacle use 24 volts, and everything else uses 12. The glow plugs are actually 12-volt plugs fed through a resistor pack on the firewall. Many civilian owners bypass the pack, fit a 12-volt starter and remove the second alternator.

Year by year

What changed, model year by model year. Sweet spot Beware

  1. 1973'Rounded Line' square body launches. The truck is 7 in longer overall on a 2.5-in longer wheelbase. The body is fully open behind the windshield, with a removable hardtop or convertible top. NP205 part-time or NP203 full-time 4WD; Dana 44 front, 12-bolt rear. Tilt wheel optional
  2. 1975400 V8 joins the K-series engine list. Chevrolet adds the Scottsdale and Silverado trims, and Silverado becomes the top trim. Catalytic converters on trucks under 6,000 lb GVWR
  3. 1976Half-cab body with a fixed steel roof over the front seats and a removable rear top, through 1991. Blazer Chalet / Jimmy Casa Grande camper (1976–77, about 1,800 built)
  4. 1977GM corporate 10-bolt front axle phased in alongside the Dana 44. Power windows and locks offered for the first time
  5. 1980Full-time 4WD (NP203) dropped from K-series. NP205s get a slip-yoke rear output
  6. 1981Facelift with available stacked square headlamps and reduced weight. NP208 shift-on-the-fly transfer case and automatic locking hubs
  7. 19826.2 L diesel V8 (130 hp / 240 lb-ft at launch). 700R4 four-speed overdrive automatic available
  8. 1983S-10 Blazer arrives, so the big truck becomes the 'Full-Size Blazer' and the 'K-Jimmy'. M1009 CUCV production begins (1983–87). The 250 six, standard through 1982, is no longer the base engine
  9. 1987Throttle-body injection on all gas engines. The trucks become the R/V series (V10 Blazer, V-Jimmy) as GMT400 pickups take the C/K name. From here on the 350 is the standard engineSweet spot
  10. 1988K5 emblems dropped; fender-mounted mast antenna replaces the windshield antenna; trip odometer
  11. 1989GMT400-style grille; NP241 transfer case; 30-spline 10-bolt axle shafts; serpentine belt on the 5.7. Cheyenne returns as the base Chevrolet trimSweet spot
  12. 1990Rear-wheel anti-lock brakes, electronic speedometer, double-sided galvanized exterior panels, rear three-point beltsSweet spot
  13. 1991Final year. 700R4 renamed 4L60; CS130 alternator. Replaced for 1992 by the GMT400 Blazer and GMC Yukon
PART 02

Specs & capability

How it’s built, what it can do, and what fits under it.

How it’s built

Mechanically, the square-body K5 is a shortened K10 pickup. It has a ladder frame, leaf springs and live axles at both ends, a transfer case bolted straight to the transmission, and the driveline mounted high to clear obstacles. Most parts are shared with GM's light trucks, which is why they're still easy to find. The details changed a lot over 19 years, so identify the axles and transfer case before you buy parts.

CHASSISLadder frame, ≈106.5-in wheelbase2.5 in longer than the 1969–72 truck; prone to cracking at the steering box
SUSPENSIONLeaf springs, live axlesFront and rear; M1009s got an extra spring leaf
FRONT AXLEDana 44 → GM 10-bolt10-bolt phased in from 1977; 30-spline shafts from about 1989
REAR AXLEGM 12-bolt → 10-boltSome 12-bolts into the early '80s; the 14-bolt is a popular swap
TRANSFER CASENP205 / NP203 → NP208 → NP241NP208 from 1981; NP241 from 1989
ENGINES250 I6 · 305/307/350/400 V8 · 6.2 dieselTBI fuel injection from 1987; 350 standard after that

Variants & engines

YEARSPLATFORMENGINEOUTPUTWORTH KNOWING
1973–1975K5 Blazer / Jimmy, full-open body250 I6 · 307 / 350 V8 · 400 V8 from 1975350: 175 hp (1973 test)Removable hardtop or convertible top over the whole body. NP205 or full-time NP203; Dana 44 front.
1976–1980Half-cab250 I6 · 305 / 350 / 400 V8—Steel roof over the front seats, removable rear top. GM 10-bolt front phased in from 1977. NP203 dropped after 1979.
1981–19861981 facelift250 I6 (early years) · 305 / 350 V8 · 6.2 diesel from 19826.2: 130 hp / 240 lb-ft at launchLighter body and new front end. NP208 with shift-on-the-fly and automatic hubs. 700R4 four-speed automatic available from 1982.
1983–1987M1009 CUCV6.2 diesel (non-emissions)155 hp / 240 lb-ftTH400, NP208, 10-bolt axles, 3.08 gears, Eaton automatic rear locker, 24/12-volt electrics.
1987–1988R/V series (V10 Blazer, V-Jimmy)305 TBI (1987) · 350 TBI · 6.2 diesel—Throttle-body injection on all gas engines. K5 badges dropped for 1988.
1989–1991Final facelift350 TBI (L05) · 6.2 diesel—GMT400-style grille, NP241, 30-spline 10-bolts, serpentine belt. Rear ABS and galvanized panels from 1990.

Capability numbers

Wheelbase≈106.5 in (2,705 mm)2.5 in longer than the 104-in 1969–72 truck (Wikipedia)
Payload (M1009)1,200 lb (544 kg)Army rating
Towing (M1009)3,000 lb (1,361 kg)Army towed-load rating; Wikipedia says six-cylinder Blazers weren't recommended for towing
0–60 mph22.5 sPopular Science, 1973, 175 hp 350, automatic, full-time 4WD
Fuel economy9.6 mpg at 45 mph (350 V8) · 13.7 mpg at 45 mph (250 I6)Popular Science steady-speed tests, 1973 and 1974
Top speed (M1009)55 mph (89 km/h)Governed, CUCV series

Wheels & tires

Bolt pattern6x139.7 (6x5.5") on half-ton K5s; 8-lug on one-ton axle swaps
LIFTBIGGEST TIREWHAT IT TAKES
Stock32 in (33 in with minor trimming)Hogback Fabrication on CK5: a stock K5 fits 32s without trimming and 33s with minor trimming. Other owners report 33s touching the inner fender at full lock and full bump. On 16-in wheels, 285/75R16 is reported not to rub. For 33x12.50s, one member suggests 15x8 wheels at about 3.5 in backspacing.
3 in33x12.50R15Offroad Design's 1988 Suburban (same chassis) ran 33x12.50R15s on 15x8 steel wheels with 3 in of lift at the front and 4 in at the rear, plus a dropped pitman arm and 4.5-in bump stops.
4 in33 in (35 in with trimming)CK5 members: 33s clear without rubbing on a 4-in lift, while 35s rub and need some trimming. Plenty of owners run 35s on 4 in with modest trimming.

Forum consensus, not a guarantee: wheel offset, tire brand and suspension wear all change clearance. Confirm before you buy.

Production & special editions

GM built the square-body K5 Blazer and GMC Jimmy for the 1973–1991 model years. In the last years, Flint Truck Assembly built the Blazer, Jimmy and Suburban.

Model years1973–1991
Assembly (1990–91)Flint Truck Assembly, Michigan
CUCV (all GM types)About 70,000 built 1983–86 (model years 1984–87), mostly 1984s; includes M1008 pickups, M1010 ambulances and M1028/M1031 variants as well as the M1009
Blazer Chalet / Jimmy Casa Grande1976–1977Pop-up camper conversion built with Chinook Mobilodge. Headroom rises from 59 to 79.5 in with the top raised. About 1,800 built; base price $9,426 in 1977
M1009 CUCV1983–1987Military K5 rated at 3/4 ton, with the 6.2 diesel, TH400, NP208, Eaton automatic rear locker and 24/12-volt electrics
PART 03

Buying one

What to pay, what to check, and how to tell a good one from a clone.

What they cost

Prices depend more on the build than the year. Clean stock trucks bring steady money, M1009s are the cheap way into a diesel K5, and LS-swapped restomods take the top results.

Project / needs work$4.5k–15k
Driver$15k–30k
Excellent / original$35k–80k
Restomod (LS / Vortec)$22k–130k

Based on the 15 most recent Bring a Trailer sales of 1973–91 K5 Blazers (August–October 2026): $4,600 to $130,000, median $29,500. Stock trucks mostly sold for $15,000–38,500, a 1991 Silverado brought $80,000, a 1984 M1009 sold for $20,500, and an LSA-powered 1973 set the top at $130,000. Nine more trucks were bid to between $8,800 and $68,000 without selling. Prices move; checked October 2026. See live listings below.

What to check before you buy

  1. 01
    Frame cracks at the steering boxThis is the classic K5 fault. On CK5 and GMSquareBody, owners say the frame cracks around and behind the steering-box bolts, often on the inside of the rail. You may not see the cracks with the box bolted on. Unbolt it if you can, or have someone rock the steering wheel while you watch for the frame moving. A properly welded reinforcement plate is fine; a bolt-on brace over an old crack isn't a fix.
  2. 02
    Rust in the usual placesCK5 members list the rockers, the front floor and the front seat-belt anchors, the rear wheel arches, the tail pan, the bottoms of the doors and tailgate, the cab mounts and the rear floor supports by the tailgate hinges. Pull up the carpet and smell for mildew. If the paint is bubbling from outside, the rust underneath is usually already serious.
  3. 03
    Tailgate window and top sealTry the rear window. It winds down inside the tailgate by crank or motor, the motor and its drive cable are known to fail, and a safety switch stops the glass going up if the tailgate isn't latched. Ask whether the top has been removed. Owners disagree on whether that always causes leaks, but the seal between the top and the body is the usual leak point.
  4. 04
    Is it really a 350?One CK5 member warns about 305s being sold as 350s, engines described as 'rebuilt' that never were, and a TH350 in a truck that should have a 700R4. Look for clean grease between the engine and transmission, which suggests nothing has been apart. Check the freeze plugs for weeping.
  5. 05
    Identify the axles and transfer caseOn the front axle, a 10-bolt cover is nearly round with no flat sides, while the Dana 44 has the familiar Dana shape. Mismatched gear ratios front and rear, or a missing front driveshaft, mean someone has swapped parts. NP205 and NP203 cases carry ID tags above the front output. On 1989–91 NP241s, a leaking slip-yoke rear output is common.
  6. 06
    Hubs and 4WD engagement1981 and later trucks came with automatic locking hubs, which seize with age. One King of the Hammers K5 owner bought a truck with a 'blown transmission' that turned out to be a transfer case stuck in neutral and seized automatic hubs. Engage 4WD on the test drive, and budget for manual hubs.
  7. 07
    Previous owners' workLook for hacked-in wiring, stereos and lights, cheap lift blocks and poor welding. One CK5 member says to pay extra for a properly done one-ton axle swap (8-lug axles) rather than a cheaply lifted 6-lug truck. Another suggests 1987–91 trucks for fuel injection, with 1989–91 the favorites.
  8. 08
    M1009 specificsCheck whether the 24/12-volt system is original or has been converted. If the resistor pack has been bypassed for 12-volt glow plugs, the starter, the alternator and the NATO slave receptacle in the grille also need dealing with. Expect 3.08 gears, 10.00-15 tires and a governed 55 mph top speed as delivered.

Spotting the real thing

After 35 to 50 years, many K5s have had engine, axle and transfer case swaps, and plenty of GMC Jimmys have been re-badged. These checks help you work out what a truck started out as.

  1. ID
    Front axleTorque King says the GM 10-bolt front cover is an oval about 11 in high by 10-1/4 in wide with no flat sides, unlike the Dana 44 cover. GMSquareBody members also note the two small ears on the 10-bolt housing. Dana 44s are typical of 1973–76, either could be fitted in 1977–78, and the 10-bolt is typical from 1979. Dana 44 and 10-bolt shafts don't interchange.
  2. ID
    Transfer caseNP205: a one-piece cast-iron case with a small three-bolt idler cover on the back and an ID tag above the front output. NP203: about 22–23 in long, in four bolted sections with a range box on the front and its tag on the chain case. NP208 (1981–88) and NP241 (1989–91) are aluminum, chain-driven cases, and the NP241's tag is on the rear of the case.
  3. ID
    305 or 350?CK5 members warn that 305s get sold as 350s. Wikipedia notes that 1981-on 305s used smaller 56 cc combustion chambers, against 76 cc. Check the casting numbers and the engine code before you pay a 350 price.
  4. ID
    Year by the front end1973–80 trucks mostly have round headlamps (Silverado-trim C/K trucks got square ones for 1980). From 1981 there's a new front end with available stacked square headlamps. The 1988 trucks lose the K5 badge and get a fender-mounted antenna. The 1989–91 trucks have the flatter, GMT400-style grille.
  5. ID
    A real M1009Genuine M1009s have the 6.2 diesel, a TH400 and an NP208, 10-bolt axles with 3.08 gears and an Eaton automatic rear locker, 10.00-15 tires, and a 24/12-volt system with two batteries, two alternators, a firewall glow-plug resistor pack and a NATO slave receptacle in the grille. Blackout lights, a brush guard and a rifle rack were standard.
  6. ID
    Model namingChevrolet badges read K5 until 1988. GM officially called it the Full-Size Blazer from 1983 and the V10 / V1500 Blazer from 1987. GMC's twin was the Jimmy, then the K-Jimmy, then from 1987 the V-Jimmy.

Recalls & service bulletins

Open recalls follow the VIN, not the model. Run yours through NHTSA before you buy, and ask the seller for dealer records showing recall work.

Check a VIN at NHTSA ↗
Notable recalls
Rear brake drum balance weights can loosen aluminum wheels ↗1982 · NHTSA 82V128000On 1982 Blazer, Jimmy and C10/C15 trucks with aluminum wheels, the drum balance weights could contact the wheel, loosen the lug nuts and break the studs (1,633 vehicles).
Composite front brake rotors can separate from corrosion ↗1988–1991 (Blazer listed for 1988–92) · NHTSA 93V119000Road-salt corrosion at the joint between the stamped steel center and cast outer section of the rotor could let them separate. The campaign covered Blazer, K10/K20, Suburban and GMC equivalents (341,364 vehicles).
The one you’ll own someday

For sale now

1973–1991 · USK5 Blazer (all square body)
1973–1980 · USRound-headlight trucks (NP205/NP203)
1987–1991 · USTBI trucks
1973–1991 · USGMC Jimmy
PART 04

Owning one

Baseline service, the repairs you’ll actually do, and where the manuals live.

Post-purchase baseline

After you buy it

Assume nothing has been done. These trucks are 35 to 50 years old, and most have had several owners and swaps. Before you buy fluids, identify the engine, transmission, transfer case and axles, since they changed every few years. Pull the steering box and look at the frame while you're under there. Capacities vary by drivetrain, so check them in the factory manual.

Engine oil & filterGrade and capacity [CONFIRM IN MANUAL]At purchase, then per manual
Air filterElement to suit engineAt purchase; inspect at every oil change

The diesels are especially sensitive to dust ingestion, so check the airbox seals.

Fuel filterGas (TBI from 1987) or diesel elementAt purchase

Old fuel and rusty tanks are common on trucks that have been sitting.

Spark plugs, cap, rotor & wires (gas)Plug type and gap [CONFIRM IN MANUAL]At purchase

Most trucks have had an ignition swap at some point, so check what's fitted before ordering.

Glow plugs & controller (6.2 diesel)12-volt plugs, including on 24-volt M1009s (resistor pack on the firewall)Test at purchase

On an M1009, find out whether the 24-volt starting system is still original before buying parts.

Coolant, thermostat, hoses & beltsCoolant type and capacity [CONFIRM IN MANUAL]Flush at purchase

Check for a leaking heater core while you're at it. One CK5 member lists it as a common annoyance. Trucks through 1988 use V-belts; the 5.7 switched to a single serpentine belt for 1989.

Automatic transmission (TH350 / TH400 / 700R4 / 4L60)ATF type and capacity [CONFIRM IN MANUAL]Pan drop, new filter and refill at purchase

Know which one you have. The 700R4 became available in 1982 and was renamed 4L60 for 1991, and M1009s use the TH400.

Transfer caseNP208 and NP241: automatic transmission fluid (ATF) · NP205 / NP203: lubricant [CONFIRM IN MANUAL]Change at purchase

The chain-driven NP208 and NP241 take ATF, not gear oil. Check the NP241's slip-yoke seal for leaks.

Front & rear differentialsGear oil grade and capacity [CONFIRM IN MANUAL]Change at purchase

The M1009's rear has an Eaton automatic differential lock. Check the gear ratio on both axles, since mismatched swaps are common.

Front wheel bearings & locking hubsRepack with wheel-bearing grease; set preload per manualAt purchase

1981 and later trucks have automatic hubs, which often seize. Plenty of owners switch to manual hubs.

Steering box, power steering fluid & frame checkPower steering fluid [CONFIRM IN MANUAL]At purchase

With the box off or the frame cleaned, look for cracks at the steering-box bolts. It's the K5's best-known weak spot.

Brake fluid, hoses & rotorsBrake fluid type [CONFIRM IN MANUAL]Flush at purchase

On 1988–91 trucks, check whether recall 93V119 (corroded composite front rotors) was done. Rear ABS arrived for 1990.

Driveshafts & U-jointsGrease greasable jointsAt purchase, then at every oil change

Lifted trucks wear driveshaft joints quickly because of the steep angles.

Battery & chargingSingle 12 V on civilian trucks; two 12 V batteries and alternators in series on M1009sTest at purchase

On an M1009, test both batteries and both alternators.

For the hands-on owner

Common repairs

The jobs owners actually end up doing, rated for a competent home mechanic with a decent tool kit. Always confirm torque figures, fluids and procedures against the factory service manual for your VIN, and work safely — support the truck on stands, never just a jack. You do this work at your own risk; see the disclaimer. Some parts links are affiliate links.

Repair and brace a cracked steering-box frame rail
DIFFICULTY · 4 / 5TIME · ≈ A weekend (more if the rail needs welding)SHOP COST · Parts plus welding labor
SYMPTOMSWandering steering, a box that visibly moves on the frame when someone turns the wheel, or hairline cracks running from the steering-box bolt holes. Big tires and hard wheeling make it worse.
THE FIXUnbolt the steering box, swing it aside and clean or blast the rail inside and out, because cracks often show only on the inside. GMSquareBody members drill a stop hole at the end of each crack, gouge it out, weld it, grind it flat, and only then add reinforcement. Offroad Design's weld-on repair kit wraps the outside and bottom of the rail. A bolt-in brace ties the box to the opposite rail and is good insurance on an uncracked frame. Some members also replace loose front-crossmember rivets with grade 8 7/16-inch bolts.
TOOLS & PARTSWelder and grinder · drill and bits · socket set · torque wrench · magnaflux or dye penetrant for hidden cracks
Swap a worn or leaking steering box
DIFFICULTY · 3 / 5TIME · ≈ 3–4 hoursSHOP COST · Parts plus labor
SYMPTOMSPlay at the wheel, wandering on the highway, fluid weeping from the box's seals, or a box that has been loosened by a cracking frame.
THE FIXInspect the frame first, because a new box on a cracked rail will soon loosen. Disconnect the steering shaft coupler and the pressure and return lines, pull the pitman arm with a puller, and unbolt the box. Fit the new box with new hardware and a new or rebuilt coupler. Refill and bleed the power steering by turning lock to lock with the front end raised. Lifted trucks often get a dropped pitman arm at the same time to correct drag-link angle.
TOOLS & PARTSPitman arm puller · flare-nut wrenches · torque wrench · drain pan
Convert seized automatic hubs to manual locking hubs
DIFFICULTY · 2 / 5TIME · ≈ 2–3 hoursSHOP COST · Parts only for DIY
SYMPTOMSThe truck won't pull with the front wheels in 4WD, grinding from the hubs, or front wheels that drive at one corner only. Automatic locking hubs arrived with the NP208 for 1981 and are now old.
THE FIXRaise and support the front, remove the wheel, then remove the automatic hub assembly, its retaining ring and the drag sleeve parts. Check the wheel bearings and the spindle nut adjustment, and repack or replace the bearings if they're dry or rough. Fit the internal-style manual hub kit to suit your axle (10-bolt or Dana 44, spline count). Then check that 2WD and 4WD both engage.
TOOLS & PARTSSnap-ring pliers · spindle nut socket · bearing grease · torque wrench
Reseal an NP208 or NP241 and fix a leaking slip yoke
DIFFICULTY · 4 / 5TIME · ≈ A day (case out of the truck)SHOP COST · Parts plus labor
SYMPTOMSATF dripping from the rear output, a driveline clunk, or a slip yoke pulling out as the suspension droops on a lifted truck. A worn chain can also skip or slap.
THE FIXBoth cases are aluminum, chain-driven and filled with ATF. Drain the case, drop both driveshafts and unbolt the case from the transmission adapter. Split the halves, check the chain for stretch and the bearings for wear, and replace all seals and gaskets. On a lifted NP241, a slip-yoke eliminator gives you a fixed rear yoke and a shorter shaft. Offroad Design's kit uses a common 32-spline yoke shortened by 1/4 inch. Refill with ATF.
TOOLS & PARTSTransmission jack · snap-ring pliers · seal drivers · RTV · torque wrench
Rebuild the front axle ends (ball joints, U-joints, bearings)
DIFFICULTY · 3 / 5TIME · ≈ A weekendSHOP COST · Parts plus labor
SYMPTOMSDeath-grip steering, clunks over bumps, uneven tire wear, a front end that won't hold alignment, or clicking from the axle U-joints in tight turns in 4WD.
THE FIXIdentify the axle first. A Dana 44 and a GM 10-bolt look alike, but CK5 members warn that the inner parts and shafts don't interchange. Strip the hubs, calipers and spindles, pull the axle shafts, press out the old U-joints and ball joints, then press in new ones. Replace the spindle bearings and seals, repack the wheel bearings and set the preload. Finish with new hub seals and a front-end alignment.
TOOLS & PARTSBall joint press · U-joint press or vise · spindle nut socket · slide hammer · torque wrench
Renew leaf spring bushings and shackles
DIFFICULTY · 3 / 5TIME · ≈ A daySHOP COST · Parts plus labor
SYMPTOMSClunks, wandering and axle wrap. Sagging rear springs are also common, and cracked rubber bushings often squeak.
THE FIXSupport the frame and take the weight off one spring at a time. Unbolt the shackle and main-eye bolts, press out the old bushings, and fit new ones that match your springs, since stock and aftermarket lift springs use different bushings. Fit greasable heavy-duty front shackles while you're there. Torque everything with the truck on the ground at ride height. Offroad Design publishes a chart of which bushing fits each stock or aftermarket spring.
TOOLS & PARTSJack stands · bushing press or vise · penetrating oil · torque wrench
6.2 diesel glow plugs and controller
DIFFICULTY · 2 / 5TIME · ≈ 2–3 hoursSHOP COST · Parts only for DIY
SYMPTOMSHard cold starts, long cranking, white smoke until warm, or a wait light that misbehaves. On an M1009, a bad resistor pack or a mixed 12/24-volt conversion can cook new plugs.
THE FIXTest each glow plug's resistance and check that power reaches each one during the glow cycle. Replace failed plugs (or all eight) and the controller or relay if it isn't cycling. On M1009s, confirm whether the truck still has the 24-volt starting system and the firewall resistor pack before you buy plugs. The plugs are 12-volt even on CUCVs, and the resistor pack drops 24 volts to 12.
TOOLS & PARTSMultimeter · deep sockets and extensions · anti-seize

Manuals & documentation

Asked on every forum

Chevrolet K5 Blazer (1973–1991) questions, answered

What's the biggest tire I can fit without a lift?

About 32 inches. Hogback Fabrication says on CK5 that a stock K5 fits 32s without trimming and 33s with minor trimming. Other owners report 33s rubbing the inner fender at full lock and full bump, but fine on the road. On 16-inch wheels, 285/75R16s are commonly said not to rub. Wheel width and backspacing matter: one member suggests 15x8 wheels at about 3.5 inches of backspacing as the easy fit for 33x12.50s.

SOURCE · CK5 FORUMS
Which years should I look for?

It depends on what you want. The 1973–75 trucks have the fully open body, and 1976–80 trucks are the classic half-cab with the old grille, NP205 or NP203 and simpler mechanicals. CK5 members tend to recommend 1987–91 for throttle-body injection, with 1989–91 the favorites for the final front end, the NP241 and 30-spline axles. One member names 1988 for its TBI 350 and revised 700R4.

SOURCE · CK5 FORUMS · WIKIPEDIA
Does mine have a Dana 44 or a 10-bolt front axle?

Look at the cover. Torque King describes the GM 10-bolt cover as an oval about 11 by 10-1/4 inches with no flat sides, unlike the Dana 44's. 1973–76 half-tons used the Dana 44, 1977–78 trucks could have either, and from 1979 Blazers used the 10-bolt through 1991, according to one GMSquareBody member's list (another CK5 member says GMC used up its last Dana 44s through 1982). Thirty-spline 10-bolt shafts came in around 1989.

SOURCE · TORQUE KING · GMSQUAREBODY · CK5
Which transfer case do I have?

Up to 1980 you'll find the gear-driven NP205, a one-piece iron case with a small three-bolt idler cover on the back, or the full-time NP203, a long four-section case with a separate range box on the front. From 1981 the aluminum, chain-driven NP208 took over, and the NP241 replaced it from 1989. The 208 and 241 both take ATF.

SOURCE · OFFROAD DESIGN · DIESEL HUB · WIKIPEDIA
Is the 6.2 diesel any good?

It's slow but simple. At launch it made 130 hp and 240 lb-ft, with a mechanical injection pump and indirect injection, and it fits the same mounts as the gas V8. Known problems include cracked main-bearing webs, and crank failures linked to worn harmonic balancers. Inspect the balancer and find out the engine's history before you buy.

SOURCE · WIKIPEDIA
What's different about an M1009?

It's a 1983–87 Army K5 with the 6.2 diesel, a TH400 and an NP208, 10-bolt axles with 3.08 gears and an Eaton automatic rear locker, heavier springs and 10.00-15 tires. It has a 24/12-volt electrical system and is rated for 1,200 lb of payload and 3,000 lb towed. GM built about 70,000 CUCVs of all types.

SOURCE · WIKIPEDIA
How does the removable top work?

On 1973–75 trucks the whole roof behind the windshield came off, with a hardtop or a convertible top. From 1976 the front roof is steel and fixed, and only the fiberglass rear top unbolts. That stayed true through 1991. Offroad Design still sells a soft top for 1969–91 K5s and Jimmys.

SOURCE · WIKIPEDIA · OFFROAD DESIGN
How good is the fuel economy?

Bad with a gas V8. Popular Science's 1973 test of a 350 automatic with full-time 4WD recorded 9.6 mpg at a steady 45 mph. A 1974 250 six with an automatic managed 13.7 mpg at the same speed. Offroad Design got 11–12 mpg on a road trip in its lifted 1988 TBI Suburban, which has the same drivetrain.

SOURCE · WIKIPEDIA · OFFROAD DESIGN
What gears do I need for bigger tires?

More than you'd think. Offroad Design put 4.56 one-ton axles under its 1988 Suburban, with a TBI 350, a 700R4 and 35-inch tires, and found it had enough rpm but still not enough power. On CK5, one member recommends at least 4.56 for 38s and 5.13s for 35-inch-and-up tires on one-ton axles. M1009s left the factory with tall 3.08s.

SOURCE · OFFROAD DESIGN · CK5
Can I put one-ton axles under it?

Yes. A Dana 60 front and 14-bolt rear from a K30 is the classic upgrade. CK5 members note that the K30's rear spring pads sit about 2 inches narrower than the Blazer's, and the perches and shock tabs need moving. Driveshaft lengths change too. The bigger brakes may also need a larger master cylinder.

SOURCE · CK5 FORUMS
What is it worth?

Prices vary a lot. Bring a Trailer's 15 most recent K5 sales (August–October 2026) ran from $4,600 for a 1986 project to $130,000 for an LSA-powered 1973, with a median of $29,500. Stock trucks mostly sold for $15,000–38,500, and a 1984 M1009 sold for $20,500. Hagerty noted in 2019 that the Blazer's median #2-condition value had risen 164% since 2009.

SOURCE · BRING A TRAILER · HAGERTY
Can it tow?

The Army rated the M1009 for a 3,000 lb towed load. Wikipedia says the six-cylinder Blazer wasn't recommended for towing. For a civilian truck, go by the GVWR, axle ratio and hitch it actually has, and check the factory trailering guide for your year.

SOURCE · WIKIPEDIA
PART 05

Building one

Who makes the good stuff, where owners gather, and who to watch.

Common modifications & who does them

SUSPENSION LIFTNew springs fix decades of sag and clear 33s. A 3–4 inch lift with a dropped pitman arm is the usual setup.
STEERING & FRAMEBrace the steering box before you fit big tires. Crossover steering and hydraulic assist are the next steps.
AXLES & LOCKERSA Dana 60 front and 14-bolt rear from a one-ton is the classic swap. On the stock axles, a locker and deeper gears go a long way.
TRANSFER CASE & LOW RANGEThe NP205 is the strong choice. Doublers and underdrives give crawl ratios, and a slip-yoke eliminator fixes the NP241's weak point.
HUBS & SOFT TOPSManual hubs replace seized automatic ones, and a soft top makes it the convertible it was meant to be.
DRIVELINE PARTSThese are common GM truck parts, so seals, U-joints and rebuild kits are cheap and easy to find.
Resources

Channels, accounts & forums

All K5 Blazer & Suburban resources →
SourcesWikipedia — Chevrolet K5 BlazerWikipedia — Chevrolet C/K (third generation)Wikipedia — Commercial Utility Cargo VehicleWikipedia — Detroit Diesel V8 engine (6.2L)Hagerty — The K5 Chevy Blazer is the new hot classic SUVBring a Trailer — Chevrolet K5 Blazer 1973–1991 resultsCK5 forums — K5 buyers guideCK5 forums — Advice needed on first K5 purchaseCK5 forums — Any tips on purchasing a K5 BlazerCK5 forums — What's the biggest tire you can put on a 1989 Blazer with no liftCK5 forums — The best tire size for stock or 2, 3 and 4 in liftCK5 forums — New wheel options, backspacing and offsetCK5 forums — Dana 44 / later 10-bolt differenceCK5 forums — D60 14-boltCK5 forums — Putting 1-ton gear in a 1991 K5GMSquareBody — K5 frame crackGMSquareBody — Steering box frame reinforcement weld-in platesGMSquareBody — Front and rear axle usage by yearTorque King — 1977–1991 GM 10-bolt front axle identificationOffroad Design — NP205 technical informationOffroad Design — NP203 technical informationOffroad Design — Axle gearing guideOffroad Design — Leaf spring bushings chartOffroad Design — Burly Burb build (1988 Suburban, 3-in lift, 33s)Offroad Design / Four Wheeler — Eddie Loomis's 1984 K5 BlazerDiesel Hub — New Process NP208 specsDiesel Hub — New Process NP241 specsNHTSA — Recall 82V128000NHTSA — Recall 93V119000Wikipedia — Chevrolet K5 BlazerWikipedia — Chevrolet C/K (third generation)Wikipedia — Commercial Utility Cargo VehicleWikipedia — Detroit Diesel V8 engineNHTSA — Recall 82V128000NHTSA — Recall 93V119000NHTSA recalls API (campaign details)Bring a Trailer — Chevrolet K5 Blazer 1973–1991CK5 forums — The best tire size for stock or 2, 3 and 4 in liftCK5 forums — What's the biggest tire you can put on a 1989 Blazer with no liftCK5 forums — New wheel options, backspacing and offsetCK5 forums — K5 buyers guideCK5 forums — Dana 44 / later 10-bolt differenceGMSquareBody — Front and rear axle usage by yearTorque King — 1977–1991 GM 10-bolt front axle identificationOffroad Design — NP205 technical informationOffroad Design — NP203 technical informationOffroad Design — Burly Burb buildDiesel Hub — New Process NP241 specs